Rear Wall Module Segmentation for Assembly Accessibility
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Solution Overview
Problem
The existing one-piece design of the rear panel and parcel shelf in passenger vehicles leads to poor accessibility during assembly, making the installation of add-on parts like seat belts and wiring complex and costly, and limits the exploitation of lightweight construction potential.
Innovation Solution
A rear panel module with integrally formed fastening elements that allow for simpler and cost-effective production, featuring a modular design with clips or snap-in connections for easy equipment arrangement and cabling, and a method for producing a motor vehicle body where the rear panel module is assembled separately and attached to the body shell after painting, eliminating the need for cathodic dip painting and improving accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the rear wall is made in one piece with the parcel shelf and joined to the body in the bodyshell, then the structural integrity is improved, but the accessibility for subsequent assembly of add-on parts and wiring becomes very poor
Solution Approach 1:
The rear wall is separated from the parcel shelf, creating independent modules. The rear wall can be assembled and equipped separately before being installed in the bodyshell, improving accessibility during assembly while maintaining structural integrity through dedicated fastening elements.
2Ease of manufacture
If the rear wall is made in one piece with the parcel shelf, then the manufacturing process is simplified, but the lightweight construction potential is not fully exploited
Solution Approach 1:
By separating the rear wall from the parcel shelf into independent modules, each component can be optimized for its specific function and weight requirements. The rear wall can be designed with appropriate thickness and material properties for structural integrity without the additional weight of an integrated parcel shelf design.
Solution Approach 2:
The rear wall module can have locally optimized thickness and material properties in different areas. Critical structural areas can have greater thickness while non-critical areas can be thinner, achieving weight reduction while maintaining necessary structural integrity.
3Productivity
If cables are fed through openings in the assembled rear panel, then the wiring is completed, but the insulation of the cables is damaged due to poor accessibility
Solution Approach 1:
The rear wall module is equipped with wiring harnesses and cables before final assembly into the bodyshell. This preliminary preparation allows workers to access the rear wall from the front or side in a controlled environment, avoiding the need to feed cables through tight openings in the assembled vehicle, thus preventing insulation damage.
4Manufacturing precision
If complex fixing methods are used for the rear wall module, then the positioning accuracy is improved, but the production costs increase
Solution Approach 1:
The fastening elements are integrated directly into the rear wall module during its manufacturing process. This merging of the fastening function into the module itself eliminates the need for separate, complex fixing mechanisms, achieving both accurate positioning and cost-effective production.
Solution Approach 2:
The rear wall module includes self-contained fastening elements that automatically engage with corresponding features in the bodyshell during assembly. This self-service approach ensures accurate positioning without requiring complex external fixing equipment or multiple assembly steps.
Data Source
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AI summary
The invention relates to a rear wall module (20) for fastening to a body of a motor vehicle, which can be provided with at least one fitting part (32, 34) before installation into the motor vehicle body (12), wherein at least one fastening element (22, 42) that is integral with the back wall module (20) is provided, with which at least one fitting part (32, 34) or wiring (18), a line or the like can be fixed to the back wall module (20), or by which the back wall module (20) can be arranged on the body (12) of the motor vehicle. The invention further relates to a method for producing a motor vehicle body (12) having such a rear wall module (20).